Legrand Upgrading from GE PLC - Switch Interface Card Installation guide

Brand: Legrand

Model: Upgrading from GE PLC - Switch Interface Card

Type: Installation guide

Legrand Upgrading from GE PLC - Switch Interface Card allows you to upgrade your older GE PLC lighting control system to the more advanced Watt Stopper Complete Control (CC) architecture. It seamlessly replaces the existing ES8 or ES16 card in an ETA panel or the SRS16 card in an SRC panel, providing programmable switch interface points. This upgrade enables integration of switch functions from a Programmed System Switch (PSS) into your existing PLC system.

Installation Instructions

Inc.

HIO16CC

Complete Control Switch Interface Card

for Upgrading PLC Panels

The HIO16CC Switch Interface

Card is an intelligent upgrade card

for a GE Programmable Lighting

Control (PLC) panel. It provides a

path from PLC to the more fully-

featured Watt Stopper Complete

Control (CC) system architecture.

Most older GE systems fall into two

categories: ETA panels with an ECON

Controller, or SRC panels with no

central controller. (Refer to the table

“Upgrading From PLC To Complete

Control” on the next page for a

summary of system components.) To

upgrade these panels to CC, simply

replace the existing Relay Controller

and Switch Interface Cards with the

new HCPU32CC and HIO16CC

modules. Upgraded panels can

coexist with older panels until the

whole system is converted to

Complete Control.

The HIO16CC Switch Interface Card replaces the

ES8 or ES16 card in an existing ETA panel, or the

SRS16 card in an SRC panel.

The motherboard in these panels requires one

HCPU32CC Relay Controller Card to provide full

monitoring and control for up to 32 relays. The switch

interface card is optional, but if one is present in the

PLC panel, it must be upgraded to an HIO16CC at the

same time as the HCPU32CC.

The HIO16CC provides programmable switch

interface points, allowing the user to integrate the

switching functions of a Programmed System Switch

(PSS) into an existing PLC system.

Features

• Simple plug-in module

• No rewiring of switches necessary

• 16 switch inputs per panel

• Use 3-wire maintained or momentary switches

• Provides system functions for Clean, Photocell,

Blink Warn and Master Switch

Note: The original type of PLC system, a BCON

Controller with BTA panels, can also be upgraded

using an additional kit, the HEMB32CAN.

Before starting, read the instructions on the next

three pages. If you have any questions, call our

Service Team at: 888-852-2778.

ETA Panel with HCPU32CC and HIO16CC upgrade card installed

HIO16CC Complete Control Switch Interface Card for Upgrading PLC Panels

CAUTION: The power supply must be off when inserting or removing cards.

These instructions assume the panel has a standard cover which exposes both

line voltage and low voltage sections. The line voltage sections must be

covered to avoid exposure to live high voltage wiring.

If an SRC system is being upgraded, DO NOT CONNECT THE DATALINE UNTIL

AFTER ALL THE PANELS HAVE BEEN UPGRADED. SRC modules will fail if

connected to the dataline.

Steps for Upgrading

1 If you are upgrading a BTA/BCON

system, install the HEMB32CAN kit

(see instructions INHEMB).

2 For all systems, next install the

HCPU32CC Relay Controller Card

(see instructions INHCPU32).

3 If switch interfaces are required, next

install the HIO16CC Switch Interface

Card per instructions below).

Installing the HIO16CC

These instructions repeat several of the

steps involved in an HCPU32CC

installation. If you have just installed the

HCPU32CC and have not yet reapplied

power, skip to Step 6. Power must be off.

1 Program the system. Before

replacing any cards, you should set

up the new system program using

CC system software HSOFT-CM1 or

WinControl. Upgraded panels must

receive an initial program from the

software in order to work. To minimize

downtime for your lighting control

system, please document your site

wiring and prepare the software

program for your site before physically

changing any hardware. Refer to the

User’s Manual supplied with the

software.

2 Turn off the circuit breakers

supplying line voltage to all relays

and the transformer in the panel.

3 Remove the panel cover.

4 Test the transformer terminals with

a voltmeter to ensure power is off.

(A red LED should be on when power

is on, and off when power is off.

However, for complete safety, check

with a voltmeter).

5 Examine the panel interior to

identify the motherboard (shown in

Figure 1), relay controller card

(ER16, ER32 or SRCM-R) and switch

interface card (ES8, ES16 or SRS16).

The relay controller card will be

plugged into the left connector

(marked

RELAY MODULE CONNECTOR) on

the motherboard. The switch interface

card will be in the right connector

(marked

SWITCH MODULE CONNECTOR).

Note the address settings on each

card.

B-GENERATION E-GENERATION SRC

Controller BCON ECON SRRP-xx in each panel

Panels BTA ETA SRSP

Relay Controller Card Built-in ER16 or ER32 SRCM-R

Switch Interface Card Built-in ES8 or ES16 SRS16

Dataline Yes Yes No

To Upgrade to Replace panel interior Replace relay card Replace relay card

the Watt Stopper with HEMB32CAN. with HCPU32CC. with HCPU32CC.

Complete Control … Install HCPU32CC and Replace switch card Replace switch card

HIO16CC cards. with HIO16CC. with HIO16CC.

Install a dataline if multiple

panels will be networked.

GREY/WHITE

LABEL STRIP

(see Step #9

on page 3 in

instructions

INHCPU32)

Figure 1 – Panel Motherboard

Upgrading From PLC To Complete Control

The following chart is designed to help you identify the components of your existing

GE Programmable Lighting Control (PLC) system, and the new components required

to upgrade to The Watt Stopper Complete Control.

6 Remove the existing switch interface

card by pulling up the Ejector Tabs

on the corners of the board. This will

“pop” the card out of the connector

on the motherboard. Then pull the

card straight out.

7 Inspect the pins in the switch

module connector on the mother-

board to ensure there are no broken

or bent pins. If any are bent, carefully

straighten them using pliers, or call

The Watt Stopper Service to replace

the motherboard.

8 Set the address of the HIO16CC

card by turning the Address Set

Knobs to the required numbers. You

should set the same address that the

old card had.

9 Slide the HIO16CC card vertically

into its slots until it rests gently on the

relay module connector pins. Make

sure the pins are properly aligned

and push the card straight in until it is

fully seated on the motherboard (you

should feel a noticeable “click”).

10 If you have maintained switches,

you must jumper red to black at the

switch input connectors.

11 Turn on the circuit breaker supplying

power to the transformer only.

12 Test the HIO16CC, using HSOFT-CM1

in the Dataline Monitor Mode (see

next page).

13 Replace the enclosure cover.

14 Turn on the circuit breakers to

restore power to the relays.

Troubleshooting

If no switches respond to the test in Step

12 above (as described in detail on the

next page), check the HIO16CC Hardware

Status LED with the low-voltage power

supply on.

If the LED is off, power is not ﬂowing to

the card. Turn off the low-voltage power

supply and reseat the card.

If the LED is ﬂashing, the card is

defective. Call 888-852-2778 for Service.

Figure 2 – HIO16CC Switch Interface Card

TOP OF CARD

BOTTOM OF CARD

CARD CONNECTOR

EJECTOR TAB

HARDWARE

STATUS LED

ADDRESS

SET KNOBS

HIO16CC Complete Control Switch Interface Card for Upgrading PLC Panels

Panel Division 888-852-2778 INHIO16 090701

Document the Site Wiring

In a networked lighting control system,

each relay panel must have a unique

address number. For CC upgrades, this

is set by the Address Set Knobs on the

HCPU32CC Relay Controller Card and

the HIO16CC Switch Interface Card.

Why do relay and switch input numbers

change when PLC is upgraded to CC?

In PLC panels, relays were set up in

groups of 16 (and switch inputs in groups

of 8) as shown in Figure 3. The ﬁrst 16

relays (and 8 switch inputs) were installed

on the RIGHT side of the panel and

numbered 1-16 (1-8). Panel addresses

were usually assigned as EVEN numbers

(Panel 002, 004, etc.). If a panel included

another 16 relays (for a total of 32), and

another 8 switch inputs (for a total of 16),

they were installed on the LEFT side of

the panel, but still numbered 1-16 (1-8).

This second group of relays and switch

inputs was considered another panel,

and was assigned the next higher ODD

number panel address. So a single tub

could include two panel addresses —

Panel 002 for the RIGHT side and Panel

003 for the LEFT side.

When PLC panels are upgraded to CC,

they can still have up to 32 relays and 16

switch inputs, but only one panel address

(which can be either odd or even) as

shown in Figure 4. Relays are numbered

1-16 on the RIGHT side and 17-32 on

the LEFT side. Switch inputs are numbered

1-8 on the RIGHT side and 9-16 on the

LEFT side. Label strips are supplied with

the HCPU32CC upgrade kit to identify

the new numbering scheme (see Steps

8 and 9 on the previous page).

When documenting your site wiring and

entering this information in HSOFT-CM1

or WinControl, review the panel addresses

to ensure there are no duplicates.

Remember that panels now have one

address for both right and left sides, and

relays are now numbered 1-32 and

switch inputs 1-16.

PANEL 003

SWITCH

INPUTS

PANEL 003

RELAYS

PANEL 002

SWITCH

INPUTS

PANEL 002

RELAYS

PANEL 003 PANEL 002

Figure 3 – PLC Panel

PANEL SWITCH INPUTS

PANEL RELAYS

PANEL 002 (or 003)

Figure 4 – Upgraded PLC Panel

HIO16CC Complete Control Switch Interface Card for Upgrading PLC Panels

Testing the System

With HSOFT-CM1 Software

Use HSOFT-CM1 in the Dataline Monitor

Mode.

1 If your computer is not connected,

select the “Connect” option to connect

to the LCP or HLINKCC device.

2 From the Main Menu, select “Monitor

and Control”.

3 From the Monitor and Control Menu,

select “Monitor Dataline”.

4 You can monitor the response of

programmable system switches one of

two ways:

a) Be in contact with a second person

at the panel to be tested while you

monitor the computer, or

b) Set up a printer to capture the

response of each switch as it is tested.

If you have a parallel printer con-

nected to the computer, simply hit the

F5 key to capture each step of the test

to the printer.

5 While watching the switch status on

the Monitor Dataline screen, physically

touch the numbered switch inputs on

the motherboard with a probe. For

each switch input, touch white

(common) to red for on, and white to

black for off.

6 Status will be indicated at the bottom

of the screen in the PSS line. For

example, “PSS – 12/1 ON” says that in

Panel 012, Input 1, the PSS is on..

If any of the switches do not respond to

the test, call Service at 888-852-2778.

With WinControl

™

Software

Use WinControl in Monitor Dataline

Mode.

1 From the WinControl Menu, select

MonitorControl, then Monitor Dataline.

2 If your computer is not connected, you

will be asked if you want to connect.

Select Yes.

3 The Monitor Dataline window will

appear.

4 Physically touch the numbered switch

inputs on the motherboard with a

probe. For each switch input, touch

white (common) to red for on, and

white to black for off.

5 The activation of each switch will be

indicated in the window for each PSS

that is probed. For example, “PSS 12/1

ON” says that in Panel 12, Input 1, the

PSS is on. Ascroll bar will appear if

there is too much activity to display in

the window.

If any of the switches do not respond to

the test, call Service at 888-852-2778.

Legrand Upgrading from GE PLC - Switch Interface Card Installation guide

Legrand Upgrading from GE PLC - Switch Interface Card Installation guide

Legrand Upgrading from GE PLC - Switch Interface Card Installation guide

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